Mechanic&#39;s seat and step stool

ABSTRACT

A combination step stool and mechanic&#39;s seat in the form of a molded plastic, generally parallelepiped configuration includes a seat on one side supported on casters on the opposite side with a step stool surface adjacent the backside of the seat and spaced from a front side surface of the seat which includes a recess tray for tools and other items.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation-in-part application of Ser. No. 10/921,507 filedAug. 19, 2004, which is a continuation-in-part application of Ser. No.10/444,228 filed May 23, 2003, entitled Mechanic's Seat and Step Stoolwhich was a utility application based upon and derived from priorprovisional application Ser. No. 60/383,206 filed May 24, 2002 for“Mechanic's Seat and Step Stool” each application being incorporatedherewith by reference and for which priority is claimed.

BACKGROUND OF THE INVENTION

In a principal aspect, the present invention relates to a molded workseat which may also be utilized as a low-rise step stool.

When a worker, such as a mechanic, tradesman, or the like is required toassume a seated position in order to perform repair work, the use of achair may not be convenient or adequate. That is, a typical chair, forexample, a folding chair, may have a seat which is elevated relative tothe work area. Additionally, such a chair is difficult to move from oneplace to another. Finally, such a chair typically will not include ameans for storage of tools for easy access while using the chair orseat.

An alternative to a chair is a stool such as a three-legged stool whichcan be moved from place to place. A stool will typically have many ofthe disadvantages associated with a chair including the furtherdisadvantage that there is no lateral or back support when sitting on astool.

Another alternative is to utilize a creeper seat. Such a seat typicallyincludes a metal frame mounted on a platform which, in turn, is mountedon rollers. The seat is supported by the metal frame. The rollers enableease of movement of the creeper seat. The platform upon which the frameis mounted allows storage of tools thereon for ease of access. LisleCorporation, Clarinda, Iowa, has marketed such seats as their ProductNos. 98302 and 98702.

Such chairs, seats and stools are either cumbersome or have otherdisadvantages as discussed above. Thus, there has remained a need for animproved seat construction which can be used by a mechanic or other workperson and which desirably has alternative utility.

BRIEF DESCRIPTION OF THE INVENTION

Briefly, the present invention comprises a molded polymeric, step stooland seat which is in the form of a six-sided, rectangular parallelepipedand includes a first wall having casters and a second opposite side wallwith a molded work seat. A third transverse sidewall connecting the topedge of the first and second walls defines a flat planar step surface. Afourth transverse wall is generally parallel to and spaced from thethird wall and connects the lower edge of the first and second wallsdefines a floor support surface including optional floor support pads toprevent skidding of the device when it serves as a step stool. Thefourth wall may also include a recess shelf for storage of tools andimplements. In an additional embodiment, the first wall may include amolded step below the level of the third wall to facilitate stepping tothe third wall step surface.

Thus, it is an object of the invention to provide a combination stepstool and creeper seat.

It is a further object of the present invention to provide a moldedpolymeric combination step stool and creeper seat which is lightweight,economical, and rugged.

Yet another object of the invention is to provide a combinationmechanic's step stool and creeper seat which includes a shelf forstorage of tools and implements when the device is oriented orpositioned as a mechanic's seat.

Yet another object of the invention is to provide a mechanic's creeperseat which may be mounted on casters for ease of mobility.

These and other objects, advantages and features of the invention willbe set forth in the detailed description which follows.

BRIEF DESCRIPTION OF THE DRAWING

In the detailed description which follows, the drawing is comprised ofthe following figures:

FIG. 1 is an isometric view of a first embodiment;

FIG. 2 is an alternative isometric view of the embodiment of FIG. 1;

FIG. 3 is an isometric view of an alternative embodiment having anintermediate step for the step stool feature of the device;

FIG. 4 is an isometric view of another alternative embodiment of thecombination seat and step stool wherein the device is oriented for useas a seat;

FIG. 5 is an isometric view of the seat configuration of FIG. 4 asviewed from the front side or forward side of the seat illustrating indetail the recess shelf for tools and implements;

FIG. 6 is an isometric view of the seat configuration of FIG. 4 asviewed from the opposite side of the seat depicted in FIG. 4;

FIG. 7 is an isometric view of the device of FIG. 4 wherein the devicehas been positioned so as to serve as a step stool;

FIG. 8 is a cross sectional view of the device of FIG. 4 takensubstantially along the line 8-8;

FIG. 9 is an isometric view illustrating another alternative embodimentof the invention;

FIG. 10 is an isometric view of the underside of the alternativeembodiment of FIG. 9;

FIG. 11 is an enlarged isometric view of a caster attached to theembodiment of FIG. 9;

FIG. 12 is a cross sectional view depicting a step in construction ofthe caster attachment feature during the manufacturing process for theembodiment of FIG. 9;

FIG. 13 is a cross sectional view of a subsequent sequential step to thestep depicted in FIG. 12 in the formation of the corner adapted forreceipt of a caster for the embodiment of FIG. 9;

FIG. 14 is a cross sectional view of an alternate method of attaching acaster to a corner of an injection or blow molded product whichalternate method is deemed to be generally undesirable;

FIG. 15 is a cross sectional view of the embodiment of FIG. 14 furtherillustrating the method;

FIG. 16 is an isometric view of an alternative embodiment of theinvention comprised of a generally parallelepiped assembly incombination with an insertable shelf assembly;

FIG. 17 is an exploded isometric view of the embodiment of FIG. 16;

FIG. 18 is an isometric view of the insertable shelf assembly associatedwith the embodiment of FIGS. 16 and 17;

FIG. 19 is a front view of the assembly of FIG. 18;

FIG. 20 is a side view of the assembly of FIG. 19;

FIG. 21 is a cross sectional view of the assembly of FIG. 19 taken alongthe line 21-21 in FIG. 19, depicting the retention mechanism used tomaintain the assembly of FIG. 18 in combination with the generallyparallelepiped assembly comprising the step stool;

FIG. 22 is an isometric view of an alternative caster retention housing;

FIG. 23 is a cross sectional view of the housing of FIG. 22;

FIG. 24 is a bottom view of the housing of FIG. 22; and

FIG. 25 is a top plane view of the housing of FIG. 22.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a combination mechanic's seat or stool and stepstool. The combination is preferably manufactured from a plasticmaterial such as polypropylene formed by a rotational mold process,injection molding, or other molding process. The overall generalconfiguration is that of a parallelepiped, in particular, a rectangularparallelepiped. The molded device may have inclined sides formed withdraft angles to facilitate the molding process as well as to improve theaesthetics, balance and utility of the product.

Referring to FIG. 1, the device is depicted to function as a step stool.FIG. 2 illustrates the device oriented to function as a creeper ormechanic's seat mounted on rollers or casters. When the item is utilizedas a step stool, as in FIG. 1, a top face 10 includes a serrated orpatterned surface to prevent slippage. A non-skid pad (not shown) mayalso be affixed to surface 10. Thus, top surface 10 is a generally flat,planar surface generally parallel to and spaced from a bottom or lowersurface 12.

A first side surface 14 includes a series of casters or wheels 16arranged at the four corners of the first side face or side surface 14.As shown in FIG. 2, the side opposite the first side surface 14comprises a second side surface 17 with a recessed seat 18 molded orformed therein. The recessed seat 18 includes parallel, spaced side ribs20 and 22 which reinforce the unit. A back support 19 is molded betweenribs 20, 22. End surfaces 24 and 26 on the second or bottom surface 12includes non-skid pads 25, 27, 32, 34. The pads 25, 27, 32, 34 preventslippage of the device when used as a step stool as depicted in FIG. 1.

Bottom or third side surface 12 is generally parallel to top surface 10and also includes a first corner support pad 32 and a second cornersupport pad 34 so that the surface 12 includes four corner pads 25, 27,32, 34 which facilitate support of the stool as depicted in FIG. 1 as astep stool.

As depicted in FIG. 1 when the combination seat and stool is oriented sothat the pads 25, 27, 32 and 34 are positioned on the floor, the supportsurface 10 is elevated above the floor. A person may thus step upon thesupport surface 10 and thereby utilize the device as a step stool.

The surface 12 also includes a recessed section 38 beneath the seat 18.The recessed section 38 includes a generally flat shelf 40 for placementof tools and other items to be used by the mechanic who is sitting inthe seat 18 and wishes to reach between his/her legs to have access to atool. As shown in FIG. 2, when sitting on the seat 18, a mechanic mayeasily move by virtue of the casters 16 engaging a floor surface.

FIG. 3 illustrates an alternative embodiment wherein the stool ispositioned as a step stool and a middle step 50 is formed in the sidesurface 14. The middle step 50 thus is positioned between two casters 16and enables the user to ascend to the top surface 10 more easily. Thetop surface 10 is subscribed by side or parallel ribs or ridges 52 and54 which provide the user of the step stool an indication that they areapproaching the side edges of the stool. It is also possible to includesuch a rib or ridge along the other surfaces or edges of the step stool.

FIGS. 4-8 illustrate another alternative embodiment of the invention. Afirst or lower or bottom wall 49 is constructed to receive casters 51positioned at the four comers of the bottom wall 49. A second oppositesidewall 54 includes lateral molded arm supports 56 and 58 with anintermediate connecting seat 60 and a back support section 62. The backsupport section includes a hand hold opening 64 to facilitate carryingor movement of the device. A third wall 66 connects the bottom wall 49and the top wall 55 and provides a step surface 66 as shown in FIG. 7.The step surface 66 includes lateral ribs 68 and 70 which define theopposite sides of the step surface 66 to indicate side margins to a userof the step surface. A fourth wall 72 is bifurcated into an upper wallsection 74 and a lower wall section 76. The upper wall section 74defines the outer margin of the seat 60. A recess tray 78 is formed inthe wall 72 between the sections 74 and 76. A recess bore 80 is definedin the back wall 82 of the tray 78 to enhance structural integrity ofthe seat and step stool construction. Non-skid pads, such as pad 84, maybe installed at the corners of the surface 72 so that when the stepstool is in the configuration illustrated in FIG. 7, that it will beprecluded from skidding undesirably. Opposite end surfaces 90 and 92 ofthe generally parallelepiped structure form the outer margins andconnecting panels which join the other described surfaces of thegenerally parallelepiped structure comprising the seat and step stool.

FIGS. 9-13 illustrate an alternative embodiment of the invention. FIGS.14 and 15 are provided for purposes of comparison with the method ofmanufacture of the stool assembly of FIGS. 9-13. That is, the embodimentof FIGS. 9-13 is a preferred embodiment. FIGS. 14 and 15 illustrate anembodiment of a caster construction for a stool which is not preferred.

Referring therefore to FIGS. 9 and 10, the step stool construction hasthe same general configuration as associated with the prior embodiments.Thus, a base 100 is generally in the form of a rectangular planarmember. Casters 102, 104 106 and 108 are affixed to the base 100 at therespective corners thereof. A lateral side 110 extends generallyvertically upward from the base 100 and terminates with an upper crossmember 112 including a handhold 114 therein. A first generally verticalside panel 116 is in opposed, spaced relation to a second opposite sidepanel 118. A top side 120 opposite the base 100 comprises a seat withside supports 122 and 124. The front side 121 of the step stool oppositethe rear or backside 110 is comprised of four support projections 130,132, 134 and 136. A pocket 138 is formed in the front side wall 121. Theembodiment of FIGS. 9 and 10 is therefore substantially similar to thatdepicted in FIGS. 4 and 5, for example.

A caster assembly 140 is provided at each of the four corners of thebase 100. Caster assembly 140 includes a wheel 142 mounted on an axle144 retained in a wheel housing 146 which is attached to a stem 148 inFIG. 13. The stem 148 is rotatably connected to the wheel housing 144 bymeans of an appropriate raceway 150. Retention spring 152 is retained ina recessed groove 154 defined in the stem 148 enabling the stem 148 tobe engaged with and locked into a bushing retained in the molded plastichousing comprising the step stool. Each of the casters 140 thus arerotatably mounted on a stem 148 and positioned appropriately in bushingsmolded into or retained at the four corners of the stool.

As previously indicated, a preferred method of manufacture of such amolded plastic stool is by blow molding techniques. However, othermolding techniques may be utilized in order to manufacture the stool.Thus, the stool is comprised of a molded plastic material, such as HDPEforming a wall such as the wall 160 in FIGS. 12 and 13. In FIGS. 12 and13 the wall 160 is a continuous molded plastic wall including a basewall 100 and a vertical back side wall 110. During the molding process,a shaft 164 is engaged with the wall 110 after the molded product isinitially formed but while the wall material is still pliable to therebydefine a recessed counterbore 166 having an end wall 168 and a lateralside wall 170 as depicted in FIG. 12. Subsequently, a caster bushing 172which is mounted on a pin associated with the blow molding equipment orrotational molding equipment is inserted through the pliable bottom orlower wall 100 so that the bushing 172 will be entirely retained withina counterbore 176. The counterbore. 176 includes a peripheral wall 180which surrounds and locks to the bushing 172. Further, there is includedan upper or top connecting wall 182 which fuses with the wall 170depicted in FIG. 12. Fusing of the walls 182 and 170 lends significantstructural support to the retained bushing 172 and thus when a caster148 is inserted into the bushing 172 the wheel assembly is wellsupported and will not fail. Note the bushing 172 includes a hollowpassage 188 adapted to receive the caster stem 148. Further included isa groove 190 adapted to receive and lock the stem 148 due to theengagement of the spring member 152 with the groove 190. Thus, asdepicted in the figures, each caster assembly is attached in a mannerwhich provides sufficient structural integrity needed to support theweight of a person, for example, on the step stool. The attachment maybe supplemented by fasteners, such as screws, which fasten a flange ofthe caster bushing.

FIGS. 14 and 15 illustrate an alternative method of insertion of abushing 172 in a molded plastic wall. After the bottom wall 100 and theback wall 110 are formed, bushing 172 is inserted or projected into thewall 100 as depicted in FIG. 14. The resulting configuration depicted inFIG. 15 does not have the structural integrity, however, needed tomaintain the wheel housing properly in the position represented by theaxis 196. The embodiment of FIGS. 12 and 13, however, accomplishes thedesired result of maintaining the wheel including the bushing 172 andthe wheel assembly 140 in a desired orientation and position.

FIGS. 16-25 illustrate a further embodiment of the invention. In thisalternative embodiment, a rectangular parallelepiped stool assembly isutilized in combination with a bucket shaped shelf assembly which may beinserted into and incorporated with the stool assembly. In other words,the step stool is a combination of the rectangular parallelepipedassembly generally as previously described with a separate, molded shelfassembly that is snap fitted through an opening cut into the molded, sixsided stool assembly.

Thus, as depicted in FIGS. 16 and 17, a rectangular parallelepiped stoolassembly 400 is combined with a shelf assembly 402. The shelf assembly402 snap fits into a side, namely a third side, of the parallelepipedstep stool assembly 400.

In the embodiment of FIGS. 16 and 17, the step stool assembly 400 isformed in a generally rectangular parallelepiped form as depicted in thedrawing FIG. 16 by a blow molding technique using a plastic material. Inthis manner, the six sides of the generally rectangular parallelepipedform are completely formed and include a front side panel 401 whichsubsequent to the formation of the step stool assembly 400 is cut out orremoved so as to reveal a peripheral rim 403. The removal of thegenerally rectangular panel 401 provides access to the interior of thestep stool assembly. It has been found to be commercially more practicalto utilize a blow molding technique to create the entire assembly 400and then remove the panel 401. Subsequently, the bucket or shelf insert402 may be positioned within the interior of the stool assembly.

The shelf assembly 402 is depicted in greater detail in FIGS. 18-21. Theshelf assembly 402 thus, is in the form of a five sided bucket with anopen front or top side 404 and one lateral side of the bucket shapeproviding a lower shelf 406. A groove 408 along lower edge 409 withhooks 410 and 412 along the upper side enable the shelf assembly 402 tobe snap fitted into an opening 414 defined between an upper wall section416 and a lower wall section 418 in third side 420 of the parallelepipedstool assembly 400 depicted in FIGS. 16 and 17. The upper and lower wallsections 414 and 416 are generally parallel or aligned with one another,thus facilitating the insertion of the bucket or shelf assembly 402.This construction provides additional structural integrity for the stool400 and also simplifies the molding process that is involved for thestool assembly.

FIGS. 22 through 25 depict an alternative sub-assembly or housing 451for attaching casters for the parallelepiped step stool assembly, suchas the step stool assembly 400. More particularly, the sub-assemblycomprises a cylindrical caster stem receiving tube or section 450attached to a generally rectangular plate or flange 452. The flange 452includes passages, such as passage 454 through which fasteners may beextended to attach the caster attachment housing or sub-assembly 451 tothe step stool, and more particularly, to a base wall of the step stool,for example, in the manner as depicted in FIG. 13 or FIG. 15. FIG. 23 isa cross section of the cylindrical section 450 and illustrates a largerdiameter counter bore section 460 connected to a narrower diametercounterbore section 462 into which a stem (not shown) of a caster may befitted. Thus, a circumferential land 464 is defined against which aretaining spring or washer will fit to retain the stem of a caster inposition within the housing 450, or sub-assembly. It is to be noted thatthe bottom side of flange 452 includes radial fillets, such as fillet468 on the outside lower surface thereof to enhance the integrity andstrength of the caster retaining housing 451. Housing 451 is otherwiseincorporated in the apertures shown in FIGS. 1, 3, 13 and 15.

The various embodiments can be made by means of a blow molding processor another thin wall or relatively thin wall molded plastic process.When manufacturing such a product using blow molding techniques, theplastic material which is utilized in the process will initially beadequately soft to permit the insertion of sub-assemblies, shafts andbushings as described above. It is to be noted that important featuresassociated with the invention include the concept of supporting thecaster retention assembly by the molded plastic and, more particularly,reinforcement of the molded material which forms the cavity for thecaster retention assembly so as to have improved structural rigidity andcapacity.

Variations from the embodiment are considered within the scope of theinvention which is limited only by the following claims and equivalentsthereof.

1. A combination step stool and seat comprising, in combination: a sixsided, unitary, hollow, single molded plastic, generally rectangularparallelepiped assembly of walls including a first side wall, an opposedsecond side wall with a molded seat, said seat including a back supportsection with a hand grip passage, a transverse third side wall betweenthe first side wall and second side walls, said third side wallcomprising a generally flat, planar step surface and said back supportsection along one side thereof, a transverse fourth side wall spacedfrom and generally parallel to the third wall for support of saidcombination assembly as a step stool, said first wall being positionableat the floor to define a creeper with a molded seat supported on themolded third side wall, said fourth wall being positionable at the floorin an alternative orientation of said assembly to define said stepstool, said fourth wall comprising an upper wall section, a spaced lowerwall section with an opening cut through the fourth wall to the interiorof the assembly; a separate molded recess shelf section in the form of agive sided bucket, said recess shelf wall section mounted to the fourthwall and comprising a bucket shaped insert with an open side openoutwardly from the fourth wall, the open side including a rim fittedinto the cut in the fourth wall and generally aligned with the wallsections of the fourth wall; and casters mounted to the first wall. 2.The combination of claim 1 wherein the second wall includes arm supportsections on each side of the molded seat extending from the back supportsection along the edge of the seat.
 3. The combination of claim 1wherein the first wall includes a molded step.
 4. The combination ofclaim 1 molded recess comprising a bushing counterbore in a moldedplastic wall with an internal counterbore top wall, said counterbore topwall fused to a molded plastic counterbore wall of an adjacentcounterbore molded in a wall adjacent the first wall to therebyreinforce the bushing counterbore, said bushing positioned to receive astem of a wheel housing.
 5. The combination of claim 4 including aplurality of bushings each retained in a said bushing counterbore moldedin a wall reinforced by an adjacent counterbore molded in a wall.
 6. Amolded plastic stool having a base support wall with an outside face anda recessed first bushing counterbore in said base support wall, saidfirst counterbore including a top wall, said first bushing counterborefurther including a bushing of a caster assembly, said stool furtherincluding a secondary, integrally molded wall extending upwardly fromthe base support wall separate from said counterbore base wall, saidsecondary molded wall including an second molded counterbore with acounterbore lateral wall fused to said top wall of the first bushingcounterbore to reinforce said first bushing counterbore, said bushingpositioned in said first bushing counterbore to received a stem of awheel housing, said first counterbore including a bushing therein withan integral peripheral flange attached to the outside of the basesupport wall.